Electrical system for internalcombustion engines



Feb. 17, 1953 w. M. BAUMHECKEL 2,629,059

ELECTRICAL SYSTEM FOR INTERNAL-COMBUSTION ENGINES Filed May 24, 1950 Patented Feb. 17, 1953 UNITED STATES.

ELECTBCAL SYSTEM FOR INTERNAL- COMBUSTION ENGINES William M. BaumheckehIndia11apolis,1nd.

Application May 24, 1950,l Serial'No. 163,950

Claims.

The. ordinary automobile or other automotive vehicle as made today commonly includes certain electrically operated apparatus, such as the ignition system of the automobile engine, the engine starter, lights, and other equipment which must be capable of functioning when the engine is not operating to generate power. To providea source of electricity for such'apparatus, it is common to employ a storage battery charged by an engine-.driven generator. In order to provide a source.r of electrical energy more dependable and of larger capacity than the conventional storage battery, it has heretofore been proposed to employ two such batteries connected in parallel to be charged simultaneously b-y the engine-driven generator. Such an arrangement operates satisfactorily as long as the two batteries and the circuits which respectively contain them are in substantially the same condition; butv if4 a condition of imbalance arises for any reason, the condition tends to become worse rather than better. For example, if one battery should begin to fail, it would receive the larger partof the current supplied to it by the generator with the result that its deterioration would be hastened, the proportion of generator current supplied to the failing battery would increase, and the better batteryV would be starved.

It is the object of my invention to provide a multiple-battery system in which a plurality of storage batteries are adapted to be charged by a single source of current and in which the charging of any battery will not be dependent upon the condition of the other battery or batteries or of the individual circuits respectively containing such other battery or batteries. Another object of my invention is to provide a simple and economical device which can be incorporated in association with an internal combustion engine, its generator, and a plurality of associated storage batteries and which will make it possible to maintain all the batteries charged to the limit of their individual capacities, while the total electrical energy available in all batteries is available for use.

In carrying out the invention, the several batteries are adapted for independent connection to the engine-driven generator by switching mechanism automatically operable to connect the batteries successively with the generator. The switch mechanism may be operated in any convenient manner to change the connections periodically, preferably at uniform intervals. Where, as in starting the engine, it is desired that the capacities of all batteries be simultaneously 2 available, switch mechanism may be provided for connecting two or more off them to the currentconsuming device or devices.

The accompanying drawings illustrate the invention: Fig. 1 is a diagrammatic illustration of the apparatus embodying two storage batteries adapted to, be charged from a common generator and so arranged that the sum of their individual capacities will be available for use in startingl an automobile engine; Fig. 2 in a side elevation in partial section and Fig. 3 is an end elevation of one form of switch and switch-operating mechanism; Fig. i is a sectional View illustrating another form of switch-operating mechanism; Fig. 5 illustrates a further modication of a switch operation mechanism; Fig. 6 is an elevation of a perferred form of control switch; Fig. 7 is a transverse section on the line 'l-l of Fig. 6; and Fig. 8 is a diagrammatic illustration of the contact arrangement employed in the switch of Figs. 6 and 7.

In Fig. l, I have illustrated an electrical system which, except for the incorporation of my invention, is of a form in common use in automobiles and other automotive vehicles. The system includes an engine-driven generator I0, a combined automatic switch end voltage regulator Il,y an ammeter i2, an ignition switch I3, a starter switch it, and an engine starter I5. In incorporating my invention in such a system, I` employ a plurality of storage batteries. TWO such batteries, identified by the reference numera-ls 20 and ZI, are shown in Fig. 1, although it will be understood that more batteries may be used if desired. Associated with the batteries is a selector switch 2,2 automatically operated by a switch-operator 23 to connect any of the batteries individually to the generator l0.

rI'he switch 22 shown in the drawing includes stationary contacts 2,5 and 26 respectively con-A nected through conductors 25 and 26 to the ungrounded terminals of the batteries 29 and 2 l, the other terminals of such batteries being grounded as indicated. Cooperating selectively with the contacts 25 and 26 is a movable contact 2l connected through a conductor 28 to the generator l. The combined automatic switch end voltage regulator Il and ammeter I2 previously referred to are connected in the conductor 28. The switch-operator 23, various forms of which will hereinafter be described, operates periodically to move the movable contact 21 out of engage,- ment with one of the stationary contacts 25 and 25 and into engagement with the ether of such contacts, lwhereby current from the generator l!) 3 will be supplied alternately to the batteries 2t and 2 I.

The ignition switch i3 shown in Fig. l is of a common type in which a movable contact connected to the conductor 28 through a conductor 5| may be moved from a neutral position either into engagement with a fixed Contact 32 or into engagement with both the fixed contact and a second xed contact 35. The first fixed contact 32 is adapted for connection through a conductor i312 with accessories such as a heater, radio-receiver, or windshield wiper, while the other contact 33 is adapted for connection through a conductor 35 with the ignition system of lthe automobile engine. The starter switch ifi shown in Fig. l is of the solenoid-operated type, its solenoid conveniently being connected to the contact of the ignition switch |55 through a starter-control switch and a conductor 31. The solenoid-operated switch lli includes a movable bridging contact 45 adapted to interconnect three fixed contacts including a contact il connected to the starter motor |55, a Contact 42 con nected to the ungrounded terminal or" the battery 2li, and a contact it connected to the ungrounded terminal of the battery 2|. When the solenoid of the switch lli is cie-energized, the bridging contact lo is out of engagement with its associa'ted xed contacts; but with the ignition switch Sli- 33 and the starter-controlled switch 35 both. closed, the solenoid will be energized to bring the bridging contact 43 into engagement with its associated iiXed contacts, whereby both batteries and 2| will be connected in parallel to the starter motor l5.

The movable Contact of the switch 22 is wide enough so that in moving from one of the fixed contacts and 2li to the other it will engage the new contact before its engagement with the other is terminated, thus insuring that the conductor 3| will always be connected to at least one of the batteries 2li and 2|.

Assuming that the rnovablD contact 21 of the switch 22 is in engagement with the xed contact 25, as shown in Fig. 1, the ungrounded terminal of the battery 25 will be connected to the conductors 23 and 3l. If the generator i5 and the engine which drives it are not operating, current from the battery 2li will be available through the conductor 3| to supply the needs of any current consuming apparatus connected to such conductor. If the generator lil is operating at a speed such that the current it produces is more than suicient to supply the needs of any currentconsuming device connected to the conductor 3i, the excess current will be supplied through switch contacts 21 and 25 to the battery 2li, thus charging that battery. When the switch-operator 25 moves the contact 2i into engagement with'the fixed Contact 25, the battery 2l is made available to supply current to the conductor 3| when the generator Iii is not operating or to receive current from the generator lll when it is op.. erating.

I contemplate that the switch operator 23 will function to move the movable contact 21 periodically between the xed contacts 25 and 25. Preferably, although not necessarily, reversal of the position of the movable contact 21 is effected at equal intervals of time when the generator l5 is providing current, .thus dividing the output of the generator substantially equally between the batteries 25 and 2|. in most vehicles, the output of the generator l il is more than adequate to maintain the charge on all the storage aoco batteries employed, and hence it is possible to maintain all the batteries charged even if the generator output is not divided equally between them.

The switch and switch-operator shown in Figs. 2 and 3, comprise a pair of nxed contacts |25 and |25 respectively corresponding to the xed contacts 25 and of Fig. l. rlhe contacts |25 and |25 are arcuate in form and are mounted in a base |56 of insulating material. A movable contact i21, corresponding to the contact 21 of Fig. 1, is mounted at the outer end of a rotating arm i5! by which it is brought alternately into Contact with the iixed contacts 225 and |26. mie arm |5| be mounted on the end of a rotating shaft |52 driven through a speed reducer |55 from the shaft |54 of the generator IU.

In the operation of the device shown in Figs. 2 and 3, the movable Contact 21 is connected Ithrough the arm 55| with the conductor 28 of Fig.

contacts |25 and |25 to connect them alternately to the conductor 25. Conveniently, the arm |5| is releasably connected to the shaft |52 so that it remain in iixed position in engagement with one of the contacts |25 and |25 while the shait |52 continues to rotate. As shown, the shaft |52 is provided with an annular groove receiving the inner end of a clamp screw |55 mounted in the arm |5|. When the screw |55 is tightened to engage the bottom o the groove in the shaft |52, the arm |5| and lthe shaft |52 are locked together for joint rotation, so that the movable contact |21 will alternately engage the iixed contacts |25 and |26. Upon release of the screw |55, however, the shaft |52 can turn freely in the arm l5! while the arm .remains stationary with the Contact |21 in engagement with one or the other of the lxed contacts |25 and |26. Where it is known that one of the batteries 2li and 2| has failed, it will be desirable to release the crew |55 and to adjust the arm i5| to bring the movable Contact |21 into engagement with the fixed con-tact associated with the good battery.

`instead of driving the speed reducing unit |53 from the generator l0, as shown in Figs. 2 and 3, such speed-reducing unit can be otherwise driven from the engine or from some independent source of power such as a low-voltage motor having no other purpose.

The switch-operator shown in Fig. 4 is a timedelay device including a solenoid 255 adapted for connection through a switch 25| and a conductor 252 to the conductor 35 of the ignition system. Associated with the solenoid 25o is a core 253 of magnetic material biased outwardly of the solcnoid by a spring The switch 25| is of the snap-action type and has an operating member controlled by spaced abutments 255 and 251 on the solenoid core 253 so as to be closed when the solenoid-core reaches a position of full eX- tension under the iniiuence of the spring 254 and to be opened when the core is retracted upon energization oi the solenoid 255.

The solenoid core is operatively connected to a diaphragm 25o defining one side of an air chamber 25|, the arrangement being such that the volume of the chamber 25| expands when the core 253 is retracted by energization of the solenoid and decreases as the solenoid-core advances under the influence of the spring 254. During advance oi" the solenoid core 253 and diaphragm y 2,1629, one

260 under the innuence oi ithe vspring 254, air escapes slowly from the chamber '26| through 7a restricted escape port 262, the size kof `such port determining ythe rate 'at which the vsolenoid kcore advances. VProvision is made for admitting air to the chamber 26| through a relatively .unrestricted passage in which there is located afcheck valve 263 which opens to admit `air freely vto the chamber 26| when its volume is increased upon retraction of the core253, but which closes during-advance of the core 253 to forcerall'air leaving the chamber 25| to flow vthrough the restricted escape yport262 and thus delay the .advance yof the core.

Reciprocation of the solenoidcore 253, in addition to operating the switch 25 l, operates 'a 'switch 222 which controls the `connection of .the generatorto Jthe batteries. The switch 222-may be of theso-c'alled ratchet type, such as is the foot-controlled switch commonly used in automobiles to control'the headlight beam. As severaliorms of ratchet switches are well known, the 'switch 222 is not 'illustrated in detail. Such a rswitch may embody an osoillatable operating member 255, and contact .mechanism (not shown) effects'the connection o the conductor 23 alternatively to the conductors 25 and 26'. The oscillata'ble `control member 255 is arranged to be received between and operated by spaced abutments256 `and 251 carriedvon the solenoid core y such de-energization having .been effected by the l abutment 256, which, in the rightward movement of the core, has engaged the switch-operating member 255 of the switch 25| and .caused such switch to open. In the condition illustrated, the spring 254 urges the solenoid core 253 and the diaphragm 26|! toward the left, displacing air from .the Ychamber' 25| through the restricted escape port 252. If the escape of air from the chamber 25| through the port 252 proceeds slowly` a considerable time interval will elapse before the solenoid core advances far enough for the abutment 251 to engage the switch-operating member 255 and close the switch 25|. When such switch is closed, the solenoid is energized to draw thecore to the right. Such rightwardmovement may proceed relatively rapidly; because the check valve 2B3'provides for the relatively free entrance of :air into the expanding chamber 26|. As the core nears the limit of its retraction, the abutment 255 engages the switch-operating member 265 and opens the switch 25|, and the resultant deenergization of the solenoid 255 permits the cycle to be repeated. The duration of each cycle is obviously dependent upon the size of the escape port 252 and the characteristics of the spring 254. As the core 253 reciprocates, the control member 265 of the switch 222 is oscillated, with the result that in each cycle of core movement such switch functions to disconnect the conductor 28 from that one of the conductors 25 and 26 to which it had been connected and to connect it to the other.

As .the device of Fig. e will be operated only when the ignition circuit is closed, it will operate only when the engine is operating and will serve as does either oi the switches 22 and |22 previously described to connect the generator alternately to the two storage batteries.

The device illustrated in Fig. 5 embodies a toggle-type, single-pole double-throw switch 322 controlled by an operating member 365 to lconnect the conductor 28 alternately to the conductors 25vl and 26. Such switch 322 is shown as operated by a vacuum-powered motor 310, which conveniently is a standard type of windshield-wiper motor connected through a conduit 31| to the intake manifold 312 of the engine 313. The motor 31@ embodies a rock shaft 314 which, when 'the motor is operating, oscillates through a predetermined arc. In adapting such a motor for use with my invention, there is secured to the shaft 314 a switch-acutating member 315 carrying spaced abutments 315 and 311 adapted to engage the operating member 365 of the switch 322. The rate at which the shaft 314 oscillates, and therefore the frequency at which the switch 322 is reversed, may be controlled by suitable constricting either the conduit 31| or the airadmitting openings of the motor.

As shown in Fig. 5, the shaft 315 and actuating member' 315 are assumed to be moving in the clockwise direction. The abutments 515 and 311 are so positioned that as the oscillating actuating member 315 nears the end oi its stroke in either direction the trailing abutment, 315 or 311, will engage the switch-operating member 365 and throw it over center to reverse the connection effected by the switch 322.

The time interval between successive operations of the selector switch 22, 22, 222, or 322, may vary widely. rFoo short an interval is undesirable, as the resultant frequency of operation is 4conducive to relatively rapid wear on moving parts. On the other hand, too great an interval is obectionable in that it might deprive one or the other of the batteries oi an opportunity to be charged during a relatively short period of engine-operation. Taking these factors into 4consideration, I prefer that an interval of about ten minutes be required for a complete cycle ci operation of the selector switch.

In selector switches of the type indicated in Fig. 2, where t. -e movable contact moves continuously duringengine operation, I prefer that it be broad enough to span the gap between the fixed contacts so lthat there never will be an `interval in which neither battery is connected `to the conductor 2S; and in this way, i insure that the conductor Si will always be connected to l'at least one of the batteries. Ratchet switches, such as that indicated at 222 and toggle switches, such as that shown at 322, operate with a snap action, and it is therefore unnecessary to make any speciiic provision for insuring against the situation in which neither battery would be connected to the conductor 3|. However, even with such switches, I nd it desirable to extend the contacts sc that there will be some slight overlapping of the intervals in which the respective batteries are connected to the generator, as arcing is thereby avoided. Except for the very brief intervals in which the conductor 28 is connected to both batteries, charging current from the generator is supplied to but one battery lat a time, and thus any lack of balance between the two batteries o-r between the independent circuits respectively containing them is immaterial; because, except for the brief intervals noted, the connected .battery receives the full charging current.

In Figs. 6, 7, and 8 I have illustrated a prefel-red form of control switch shown as comprising two relatively movable members, one an elongated, open-bottomed casing 55 and the other a slide 55| longitudinally movablein such casing. 'Ihe slide is provided with an opening and the casing with elongated slot for the reception of a circular key lt having at its inner' end a plurality of grooves which, when the key is in place, position sectioned pins to permit sliding movement of the slide itil in the casing 490. The open bottom of ythe casing itil is closed by a plate L3M of insulating material carrying a group ci ed electrical contacts the interconnection of which is effected by the slide Ilil. As shown, the fined contacts comprise an elongated contact Elta connected to the conductor 3! oi' l. and a parallel series of contacts 32', 33', and connected respectively to the conductors dll, `and shown in 1. A movable bridge contact Stb is embodied in the slide 49! tc connect the fixed contacts progressively to the contact Zilla.

In the on position of the switch shown in Figs. 6, 7, and 8, all the bring contacts Sill) are out of engagement with the ne@ contacts. Ii the key is not in place, sect ons o' the pins 495 will lie in both casing ad and slide till, and hence will prevent incvc.A ent or the slide. Upon insertion of the hey. however, eac section of each pin is positioned either enti "ely in the casing lilo or entirely in the fliil with the result that the slide ii e to move. its slide moves to the right, the bridge con c the xed contacts and g the conductor 34 and ssc elated with it to a storage battery thro du :tor 3l and the selector switch. As ine lili s moved iarther, the bridge Contact, while maintaining its engagement with fired, cc t and moves into engagement with the fixed contact 33', thus connecting .both the conductors 34 and to a battery. las the moves stfurther to the right, the bridge contact en.J the xed contact it to connect the starter. i with the battery, while still remaining in engagement with the contacts and to maintain the accessories and the ignition system connected to the battery. In this third position of the slide 40E, the winding of the starter switch it will be energized to close that switch and cause a supply of current -to the starter motor and start the engine, as previously set forth.

Desirably, there is mounted in the casing 48? a spring-pressed plunger dill nllich engages the slide dill as it is moved into tne third position.

above described and urges it to the it will be necessary for an operator to apply force to the slide in order to the starter-switch lll closed. Upon release ci such force, Ithe spring-pressed plunger' tilt' forces the Slide to the left to break the Starter-switch circuit, while leaving accessory and ignition circuits closed.

I claim as my invention:

1. In an electric system, the combination with a source or current and two storage batteries, or a current-to-battery circuit for each battery; a battery-output circuit; an electric switch for interconnecting said circuits with both of said batteries characterized by a structure simultaneously interconnecting said current-to-battery circ-it selectively to either one alone of said batteries and that battery to said output circuit, and further characterized by interconnecting current-to-battery circuit to both ot said batt-cries in parallel and placing both of said batteries in parallel connection with said battery-output circuit prior to interrupting said current-to-battery and said battery-output circuits with said prior left, so that to continue connected battery; and means cyclically operating said switch to switch said current-to-battery and said output circuits from one battery to the other; whereby each battery is normally alternately and separately discharged and charged without interruption of either of said circuits during the interval of switching of those circuits from one battery to the other.

2. The combination with an internal combustion engine; an engine driven generator; a generator output automatic switch and voltage regulator; two storage batteries; and a battery discharge circuit; of a switching mechanism interconnecting,T said generator output with either one of said batteries individually for charging and simultaneously interconnecting that output interconnected battery to said discharge circuit leaving said other battery disconnected from both said output and said circuit; said switching mechanism further having means in switching said output and said circuit from one battery to the other to have an intermediate dwell period wherein both said output and said circuit are ininterconnected with both batteries in parallel; and cycling means for operating said switching mechanism during operation of said generator.

3. The combination with an internal combustion engine; an engine driven generator; a generator output automatic switch and voltage regulator; an engine starter motor; and a plurality of storage batteries; and a battery discharge circuit; of a switching mechanism having means interconnecting said generator output with one at a time of said batteries and also interconnecting that generator-connected battery with said discharge circuit, means interconnecting said generator output with a second one alone of said batteries and said second battery to said circuit and neans interconnecting said output in parallel with both of said batteries and interconnecting both of said batteries with said circuit and maintaining said parallel connections only during the period of switching over of said output and said circuit from one battery to another; and means for actuating said switching mechanism for alternate making oi" said interconnections in timed sequence.

4. The combination with an internal combustion engine; an engine driven generator; a generator output aromatic switch and voltage regulator; an engine starter motor; and a plurality of storage batteries; and a battery discharge circuit; or a switching mechanism having means interconnecting said generator output with one at a time said batter'es and also interconnectir f that generator-connected battery with said o charge circuit, means interconnecting said generator output with a second one alone of said batteries and said second battery to said circuit and means interconnecting said output in parallel with both of said batteries and intel'- connecting both ci said batteries with said circuit and maintaining said parallel connections only during the period ci switching over of said output and said circuit from one battery to another; and means for actuating said switching mechanism for alternate making of said interconnections in timed sequence; and a starter motor control switch having means interconnecting said batteries in series with said starter motor.

5. That method of controlling charging and discharging of a plurality of storage batteries and maintaining uninterrupted current llow, which comprises the step of charging individually one of said batteries for an interval of time; charg- 9 ing individually a second one of said batteries for an interval of time; charging both of said batteries in larallel for an interval of time in changing the charging over` from the one battery to the second battery; and discharging each battery in that interval of time only during its time of charging.

WILLIAM M. BAUMHECKEL.

REFERENCES CITED 'Ihe following` references are of record in the le of this patent:

`g 2 UNITED STATES PATENTS Number 10 Name Date Moskowitz July 16, 1895 Chamberlain Apr. 24, 1900 Cowen Oct. 1J 1901 Ellicott May 12, 1903 Cormick Oct. 20, 1908 Wilson Oct. 20, 1908 Crouch et al. Aug. 22, 1911 Coleman Mar. 17, 1914 Beach Nov. 8, 1921 Schmidt June 29, 1937 Mitchell Oct. 19, 1937 Doman Sept. 27, 1938 Loehr et a1 Sept. 27, 1938 Dreischer Mar. 28, 1939 Dugan Sept. 12, 1950 Germak Aug. 21, 1951 

